Design and Fabrication of a Longitudinal Vibration Transmitter for Ultrasonic-Vibration Assisted Milling

The increase in materials with high mechanical capabilities has increased the number of advanced production methods. One of these methods is the merging of ultrasonic vibrations with conventional machining methods. The milling process is flexible in making different geometric shapes of the workpiece. In this paper, the longitudinal vibrations assisted milling process is studied. The main problem with this process is the transmission of ultrasonic vibrations to the cutting area. Therefore, different transfer methods were studied and analyzed and the most efficient method was presented. Longitudinal vibration equations for the horn were analyzed and different types of horns were designed. The best horn was identified and fabricated in terms of increased vibration amplitude and less stress. It was shown that the 5-element horn is the best option for vibration transmission. In order to transfer electrical energy to the rotary ultrasonic converter, a new tool was designed and manufactured. By machining thin-walled parts, it was shown that the fabricated tool can create appropriate dimensional accuracy in the workpiece.